Cost and Weight Optimization with Stress Analysis of Connecting Rod used in Diesel Engine using FEM Approach

Mechanical Engineering

An optimization study was performed on a steel forged connecting rod with a consideration for improvement in weight and production cost in that. Since the weight of the connecting rod has little influence on its total production cost, the cost and the weight were dealt with separately. Weight reduction was achieved by using an iterative design procedure. Literature survey suggests cyclic loads comprised of static tensile and compressive loads are often used for design and optimization of connecting rods. In this study weight optimization is performed under a cyclic load comprising dynamic tensile load and static compressive load as the two extreme loads. Constraints of fatigue strength, static strength, buckling resistance and manufacturability were also imposed. The fatigue strength was the most significant factor in the optimization of the connecting rod. An cost calculation for materials cost savings is also made.

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